Starter system for an engine

ABSTRACT

Outdoor power equipment includes an internal combustion engine including an electric motor, a battery receiving port, a rechargeable battery removably attached to the battery receiving port, wherein the rechargeable battery is configured to power the electric motor to start the engine, an implement driven by the internal combustion engine, a release mechanism movable to an engaged position to put the implement in a ready-to-run condition in which the implement is ready to be driven by the engine, a run sensor configured to detect the ready-to-run condition, a switch actuated by the release mechanism, and a control module coupled to the switch so that the switch provides a signal to the control module when the release mechanism is in the engaged position and the control module turns on the electric motor to start the engine in response to the signal from the switch and the run sensor detecting the ready-to-run condition.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application is a divisional of U.S. application Ser. No.14/507,247, filed Oct. 6, 2014, which is a continuation of U.S.application Ser. No. 13/692,739, filed Dec. 3, 2012, which is acontinuation-in-part of application Ser. No. 13/289,613, filed Nov. 4,2011, now U.S. Pat. No. 8,733,072, all of which are incorporated hereinby reference in their entireties.

BACKGROUND

The present invention generally relates to internal combustion enginesand outdoor power equipment powered by such engines, such as lawnmowers, snow throwers, portable generators, etc. More specifically, thepresent invention relates to a starter system and energy storage systemfor an engine.

Outdoor power equipment may use an internal combustion engine to drive atool of the equipment, such as a rotary blade of a lawn mower or anaxial cam pump of a pressure washer. Typically the outdoor powerequipment includes a brake mechanism that selectively prevents or stopsrotation of the tool. The brake may stop a flywheel of the engine,correspondingly stopping the crankshaft and rotating tool coupled to thepower takeoff of the crankshaft.

Starting the braked outdoor power equipment may be cumbersome, requiringrelease of the brake followed by activation of the engine. For lawnmowers and other types of outdoor power equipment, release of the brakemay include rotating a bail to draw an inner-wire of a Bowden cable thatlifts the brake mechanism. Then, activation of the engine typicallyfurther includes manually pulling a recoil starter rope or activating anelectric starter for the engine. A need exists for a less-cumbersome andfaster process to start the outdoor power equipment.

Furthermore, the outdoor power equipment may include the engine mountedto a frame or a base plate. If an electric starter is included, thestarter motor is typically connected to an interface on the handle ofthe outdoor power equipment so that the operator may activate thestarter motor while standing in an operational position, such as behindthe handle. During assembly of the outdoor power, a power source,control circuitry, and wiring associated with the starter motor arecoupled to the handle, the frame, and the engine, the attachment ofwhich may be a time-consuming and labor-intensive process. A need existsfor an engine having a starter motor that facilitates efficient assemblyof the outdoor power equipment.

SUMMARY

One embodiment of the invention relates to outdoor power equipmentincluding an internal combustion engine including an engine cover, anelectric motor configured to start the internal combustion engine, abattery receiving port, a rechargeable battery removably attached to thebattery receiving port, wherein the rechargeable battery is configuredto power the electric motor to start the engine an implement driven bythe internal combustion engine, a release mechanism movable to anengaged position to put the implement in a ready-to-run condition inwhich the implement is ready to be driven by the internal combustionengine, a run sensor configured to detect the ready-to-run condition, aswitch actuated by the release mechanism, and a control module coupledto the switch so that the switch provides a signal to the control modulewhen the release mechanism is in the engaged position and the controlmodule turns on the electric motor to start the internal combustionengine in response to the signal from the switch and the run sensordetecting the ready-to-run condition.

Alternative exemplary embodiments relate to other features andcombinations of features as may be generally recited in the claims.

BRIEF DESCRIPTION OF THE FIGURES

The disclosure will become more fully understood from the followingdetailed description, taken in conjunction with the accompanyingfigures, in which:

FIG. 1 is a perspective view of a lawn mower according to an exemplaryembodiment of the invention.

FIG. 2 is a perspective view of a handle for outdoor power equipmentaccording to an exemplary embodiment of the invention.

FIG. 3 is a perspective view of a handle for outdoor power equipmentaccording to another exemplary embodiment of the invention.

FIG. 4 is a schematic diagram of a starter system for an engineaccording to an exemplary embodiment of the invention.

FIG. 5 is a perspective view of components of a starter system foroutdoor power equipment according to an exemplary embodiment of theinvention.

FIG. 6 is a perspective view of an engine assembly according to anexemplary embodiment of the invention.

FIG. 7 is a perspective view of a battery charging station according toan exemplary embodiment of the invention

FIG. 8 is a perspective view of a battery being coupled to an engineaccording to an exemplary embodiment of the invention.

FIG. 9 is a perspective view of a starter for the engine assembly ofFIG. 6 according to an exemplary embodiment of the invention.

FIG. 10 is a circuit diagram of a controller for a starter of an engineaccording to an exemplary embodiment of the invention.

FIG. 11 is a circuit diagram of a controller for a starter of an engineaccording to another exemplary embodiment of the invention.

FIG. 12 is a perspective view of a pressure washer according to anexemplary embodiment of the invention.

FIG. 13 is a schematic diagram of outdoor power equipment according toan exemplary embodiment of the invention.

FIG. 14 is a front view of a control module of the outdoor powerequipment of FIG. 13.

DETAILED DESCRIPTION

Before turning to the figures, which illustrate the exemplaryembodiments in detail, it should be understood that the presentapplication is not limited to the details or methodology set forth inthe description or illustrated in the figures. It should also beunderstood that the terminology is for the purpose of description onlyand should not be regarded as limiting.

Referring to FIG. 1, outdoor power equipment, in the form of a lawnmower 110, includes an internal combustion engine 112 coupled to arotary tool, such as the blade in a deck 114 of the lawn mower 110, anauger, a saw, tines, a drill, a pump, or other rotary tools. In someembodiments, the lawn mower 110 further includes wheels 116 and arearward extending handle 118 designed to be pushed by an operatorwalking behind the lawn mower 110. In other contemplated embodiments,the outdoor power equipment may be in the form of a rotary tiller, apressure washer, a snow thrower, a lawn tractor or riding mower, anedger, a portable generator, or other equipment, with a correspondingpowered tool, such as tines, a pump, an auger and impeller, analternator, a drive train, or other tools.

Still referring to FIG. 1, the lawn mower 110 includes a starter system.According to an exemplary embodiment, the starter system includes anelectric motor 120 that is selectively coupled to the engine 112 suchthat the electric motor 120 is configured to rotate the crankshaft ofthe engine 112 to start the engine 112, and is then configured todisengage once the engine 112 is running. In some embodiments, the motor120 is fastened to the engine 112, such as being mounted on top of or toa side of the engine 112. Gearing (e.g., gear reduction, transmission)may extend between the motor 120 and the crankshaft of the engine 112,or the motor 120 may be connected directly to the crankshaft of theengine 112.

According to an exemplary embodiment, an operator may engage the startersystem via the handle 118 of the lawn mower 110. In some embodiments,the handle 118 includes a lever 122, button, toggle, or other interfacethat the operator may use to command the starter system to start theengine 112. In some embodiments, the command is relayed from the handle118 via a linkage 124, such as an electric wire transmitting anelectrical signal, a Bowden cable communicating a mechanical signal, oranother type of linkage. In contemplated embodiments, a transmitter andstart button are coupled to the handle (e.g., clipped on, integrallymounted with), and the starter system includes an integrated receiverconfigured to receive commands wirelessly provided by the transmitter tostart the engine. According to an exemplary embodiment, the command fromthe operator is received directly or indirectly by the motor 120, andthe motor 120 rotates the crankshaft to start the engine 112.

In some embodiments, the starter system is integrated with a bail 126 ofthe lawn mower 110. A brake mechanism (e.g., friction brake, ignitioninterrupt switch or circuit, etc.) may be holding the blade or othertool, locking the crankshaft of the engine 112, or otherwise preventingoperation of the power equipment. When the operator actuates the bail126 to release the brake mechanism from rotating members (e.g., blade,crankshaft, power takeoff, flywheel) of the lawn mower 110, the actionsimultaneously actuates the motor 120 to start the engine 112. As such,releasing of the brake mechanism synergistically also starts the engine112, easing operation of the lawn mower 110 or other outdoor powerequipment by reducing the steps necessary for activation.

In some embodiments, the lawn mower 110 includes an interlock 128 (e.g.,lock-out device, signal interrupt) to prevent release of the brake andengagement of the motor 120. According to an exemplary embodiment, theoperator must release the interlock 128 before the bail 126 can beoperated to engage the motor 120 to start the engine 112. Differenttypes of mechanical and electrical interlocks may be used in varyingcontemplated embodiments to prevent inadvertent release of the brake andstarting of the engine, such as when a user moves the power equipmentinto or out of a garage or storage shed by grabbing the handle, or ifthe bail is unintentionally bumped. Furthermore, engagement of theinterlock 128, in some embodiments, is also configured to preventinadvertent release of the brake when the handle 118 is being foldedover the deck 114 to put the lawn mower 110 in a storage configuration.

In some embodiments, the interlock 128 may prevent a signal from beingsent via the linkage 124 to engage the motor 120 and release the brake.The interlock 128 may physically disconnect the linkage 124 from thebail 126, such as by removing a linking pin that joins the bail 126 tothe linkage 124, removing a clamp that holds the linkage 124 to the bail126, or otherwise physically separating the bail 126 and linkage 124.Release of the interlock 128 then physically or electrically connectsthe bail 126 (or other brake release) to the controller 132 (e.g.,control system, control circuit, computerized controller) such thatoperation of the bail 126 is communicated to the controller 132 tosimultaneously start the engine 112.

In other embodiments, the interlock 128 physically prevents (e.g.,blocks, holds, jams) rotation of the bail 126 when the interlock 128 isengaged. In some such embodiments, a cam may be rotated into or out ofthe path of the bail 126, optionally preventing rotation of the bail126. In other such embodiments, a clamp of the interlock 128 may bindthe bail 126 to the handle 118, preventing rotation of the bail 126until released. In still other such embodiments, a sleeve or latch mayslide over the bail 126, holding the bail at a fixed angle untilreleased. The mechanical interlock described in this paragraph may beused in an embodiment where no electrical wiring harness on the handle118 is required to support the starting of the electric motor 120 andengine 112.

In contemplated embodiments, an electrical signal may indicate to thecontroller 132 that the interlock 128 has been released, such as asignal communicated via the linkage 124, via radio frequencycommunication, hardwired, or otherwise. The signal is provided inaddition to a separate signal associated with movement of the bail 126.Without the signal indicating release of the interlock, the signalassociated with movement of the bail will not be sufficient to instructthe controller to start the engine. The electrical signal may beassociated with a pass code, a key, a scanned finger print, or otheraccess-limiting device.

According to an exemplary embodiment, the lever 122 (e.g., interface,release mechanism, trigger) may serve to release the interlock 128,allowing operation of the bail 126 to release the brake and to start themotor 120. In some embodiments, pulling of the lever 122 may move aphysical obstacle out of the rotational path of the bail 126. In otherembodiments, pulling of the lever 122 may mechanically or electricallyconnect the bail 126 and the linkage 126. Other mechanisms, such asbuttons, switches, toggles, dials, etc., may serve as release mechanismsto release the interlock 128. In some embodiments, conventionalmechanical rotational interlocks or electrical switches (e.g., signaldisconnects) are used as the interlock.

In general, integration of the starter system with a handle of outdoorpower equipment allows the operator to start the engine from the rear ofthe outdoor power equipment, such as several feet from the powered toolof the outdoor power equipment (e.g., snow thrower auger, lawn mowerblades). Further, the integration supports an electric starting systemfor a walk behind mower that can be engaged by a user without actuationof a key or push-button. In other embodiments, the starter system mayinclude a start button or other interface to engage the starter systemthat is located on the engine or elsewhere. For example, in contemplatedembodiments, such an interface may include a smart phone application orremote control that wirelessly provides a start command or authorizationcode to a receiver coupled to the outdoor power equipment.

According to an exemplary embodiment, the starter system furtherincludes an energy storage device 130 (e.g., electrical storage device)and a controller 132. The energy storage device 130 may include one ormore batteries, capacitors, or other devices. When the operator engagesthe starter system, the linkage 124 communicates the command to startthe engine directly or indirectly to the controller 132, whichelectrically connects the energy storage device 130 to power the motor120. In some embodiments, the controller 132 is coupled to a governor ofthe engine 112 (see, e.g., speed sensor 420 as shown in FIG. 4), anddisengages the motor 120 (e.g., cuts power to the motor 120, high-sideswitching of the battery power source, low-side switching of the groundside of the circuit) when the engine 112 is running at a sufficientspeed.

In some embodiments, the motor 120, the energy storage device 130, andthe controller 132 are fastened directly to the engine 112, which may beconfigured for efficient assembly of outdoor power equipment using theengine 112. As such, the starter system in some embodiments may comefully assembled with the engine 112 and ready for connection to alinkage configured to provide a signal from the handle (e.g., linkage124). In some embodiments, an interface (e.g., start button, toggle,switch) for starting the engine is positioned on the engine itself, andno additional connections are necessary—the manufacturer need onlyattach the engine to the deck or corresponding feature and attach thetool to the power takeoff of the engine. In any such case, considerabletime and effort may be saved during the manufacturing process and apotential source of manufacturing difficulty may be removed (i.e., thatassociated with the fastening and electrical connection of thecomponents of the starter system during assembly of the outdoor powerequipment). In still other embodiments, some or all of the starterassembly may be fastened to the deck of a lawn mower or correspondingfeature of other power equipment.

Referring to FIGS. 2-3, handles 210, 310 for outdoor power equipment,such as a lawn mower, rotary tiller, snow thrower, etc., each include abail 212, 312 and an interlock 214, 314 with a release button 216, 316.In contemplate embodiments, the release button 216, 316 may release thebail 212, 312 from being interlocked by allowing the bail 212, 312 tomove, or by coupling the bail 212, 312 and linkage 124. In FIG. 2, therelease button 216 is to the side of the bail 212, while in FIG. 3, therelease button 316 for the interlock 314 is on top of the bail 312. Therelease button 216 of FIG. 2 may disengage a member from blockingmovement of the bail, while the release button 316 may connect the bail312 and linkage 124. In other contemplated embodiments, release buttonsor other release mechanisms may be positioned elsewhere on the handle,the engine, or on another component of the outdoor power equipment.

Still referring to FIGS. 2-3, in other contemplated embodiments, thebuttons 216, 316 may be used to provide a signal directly or indirectlyto a motor to start an engine, without regard to the bail 212, 312.However, integrating the buttons 216, 316 with the bail 212, 312 allowsfor a two-step process to start the engine (i.e., release interlock andoperate bail), while synergistically using the operation of the bail212, 312 to both release the brake as well as to engage the starter. Instill other embodiments, other forms of interlocks and releasemechanisms for the interlocks may be used, such as a biased lever (seelever 122 of interlock 128 as shown in FIG. 1), latch, thumb-printreader, etc.

In some embodiments, a three-step process is used to engage the powerequipment, such as first disabling or releasing an interlock; secondpresenting a key, a code, or other device to release an access-controlmechanism (e.g., lock out, lock); and third pulling the bail. Inalternate embodiments, the key hole or interface for the access-controlmechanism may be positioned on the handle or on the engine.

Referring to FIG. 4, outdoor power equipment 410 (shown schematically)includes an engine 412 and a powered tool 414 (e.g., rotary blade)driven by the engine 412. In some embodiments, a motor 416 is coupled tothe engine 412, and the powered tool 414 is coupled to a power takeoff418 of the engine 412. A speed sensor 420 (e.g., governor) may becoupled to the engine 412 to regulate the speed of the engine 412. Also,a brake 422 may be coupled to a rotary member of the outdoor powerequipment 410, such as the flywheel of the engine, the power takeoff 418of the engine, etc., to stop the engine as well as the associatedpowered tool.

In some embodiments, the outdoor power equipment 410 includes a handle424 having a release mechanism 426, where the release mechanism 426 isconfigured to allow a user to release the brake 422 from the handle 424.The release mechanism 426 may allow a user to release the brake 422 byengaging the bail (or other element) with a linkage connected to thebrake 422, or by disengaging an element blocking movement of the bail.The handle 424 may be coupled to the engine 412 and tool 414 directly,or via an intermediary member (e.g., deck 114 as shown in FIG. 1). Theengine 412 may further include a battery 428 for powering the motor 416and a control system 430 for operating the motor 416.

According to an exemplary embodiment, the control system 430 isconfigured to receive inputs associated with the release mechanism 426.In some embodiments, when the release mechanism 426 is actuated torelease the brake 422, the release mechanism 426 triggers a switch 432,which provides to the control system 430 a signal that is indicative ofthe release of the brake 422. The signal may be provided via amechanical linkage, wirelessly, a hardwired electrical connection, orotherwise. In some embodiments, the control system 430 then actuates themotor 416 to start the engine 412 or uses the information in controllogic configured to start the engine as a function of the status of thebrake and other factors. As such, operation of the release mechanism 426may simultaneously provide a start signal to the control system 430 aswell as release the brake 422. No additional operations to start theengine 412 may be required.

According to an exemplary embodiment, the control system 430 isconfigured to receive additional inputs from the speed sensor 420 oranother component of the engine 412 (e.g., ignition circuit). The speedsensor 420 or other component provides the control system 430 withinformation associated with the speed of the engine 412. When the engine412 is running at a sufficient speed, the control system 430 thendisengages the motor 416 (e.g., turns off, disconnects, cuts power to,etc.).

In contemplated embodiments, the control system 430 associated with thestart system may receive additional or different inputs used to controlstarting of the engine, such input from a sensor configured to indicatewhether the outdoor power equipment has moved recently. Movement of anaxle or wheels of such outdoor power equipment may trigger a sensor thatprovides a signal to the control system. The signal, in combination withan electric timer providing time-related context for the movement, mayserve as an additional indicator that the operator intends to activatethe engine. In contemplated embodiments, the control system 430 includesa timer and is configured to deactivate the motor if the engine has notstarted within a predetermined amount of time. In some contemplatedembodiments, the control system 430 includes a temperature sensor and isconfigured to prime the engine with an automated primer pump or adjustthe choke or throttle plate if ambient temperature is above or below apredetermined temperature, if a portion of the engine is above or belowa predetermined temperature, or if the difference between ambient andengine temperature is above or below a predetermined amount. Incontemplated embodiments, the control system 430 may also provide asignal output to the operator, such as a visible indicator on a displaycoupled to the handle or engine, or an audible alert. In some suchembodiments, the signal output may include as an error message, alow-fuel message, a replace-oil message, or another such message.

Referring to FIG. 5, components of a system 510 include a brake cable512 (e.g., Bowden cable) and a brake pad 514 for an associated engine ofoutdoor power equipment. According to an exemplary embodiment, the brakecable 512 is configured to be coupled to the bail of a handle of outdoorpower equipment (see, e.g., bails 126, 212, and 312 as shown in FIGS.1-3). When an operator activates the bail, the brake cable 512 moves apivot 516 coupled to the brake pad 514. The brake pad 514 then releases,allowing the engine associated with the system 510 to drive a poweredtool of the outdoor power equipment.

According to an exemplary embodiment, the engine associated with thesystem 510 further includes a starter system including a switch 518, anelectronic control 520, a battery 522, and an electric starter motor524. When the operator activates the bail to lift the brake pad 514, thepivot 516 simultaneously activates the switch 518. The switch 518 thenprovides a signal to the electronic control 520 that the brake pad 514has been lifted and that the electronic control 520 may start the engineassociated with the system 510 with the electric starter 524. Theelectronic control 520 then connects the electric starter 524 to thebattery 522. The switch 518 may be a switch already associated with thebrake, but used to provide signals to both an actuator of the brake andthe starter system (e.g., ignition ground), or the switch 518 may be anadditional switch solely used for the starter system.

Still referring to FIG. 5, the electronic control 520 includeshard-wired circuitry and is configured to receive additional inputs fromthe engine associated with the system 510. In some embodiments, theadditional inputs include an indication of the speed of the engineassociated with the system 510 from a governor or other component of theengine (e.g., electrical pulses from the ignition system). Theadditional inputs may include a current state of the engine associatedwith the system 510, such as whether the engine associated with thesystem 510 is running, etc. The starter system is also coupled to aground 526.

Referring to FIGS. 6-9, an engine 610 includes an exhaust 612, a fueltank 614, an engine cover 616, an air intake 618 for combustionprocesses, an air intake 620 for cooling the engine, and a startersystem having an energy storage device, such as a battery 622, acapacitor, multiple batteries or capacitors, or another energy storagedevice. Applicants note that the engine 610 of FIGS. 6-9 mirrors theengine 112 of FIG. 1, and both are single-cylinder, four-stroke cycle,vertically-shafted, small engines. Other engine types and designs may beused, such as engines that are horizontally-shafted, two- or morecylindered, diesel powered, cold-weather structured, etc.

Although shown as proximate to the fuel tank 614 and exhaust 612 inFIGS. 6 and 8-9, the energy storage device may be positioned elsewhereon the exterior and/or in an internal port of the engine 610. In someembodiments, where the energy storage device is sensitive to hightemperature, it may be preferred to position the energy storage deviceaway from the exhaust 612, which may become hot during operation of theengine 610.

According to an exemplary embodiment, the energy storage device isconfigured to power a starter motor (see, e.g., motor 120 as shown inFIG. 1) integrated with the engine 610. In some embodiments, the energystorage device may be further configured to power other systems of theengine 610, such as an engine control unit (ECU) having controlcircuitry coupled to sensors or detectors integrated with the engine(e.g., brake release, fuel-level detector, ignition-fouling detector,governor, etc.).

According to an exemplary embodiment, the energy storage device is thebattery 622, which is rechargeable. As shown in FIG. 7, the battery 622may be charged at a charging station 624 or may include a charging portintegrated with the battery (e.g., battery pack with charging port toreceive a connection from a wire coupled to an outlet or the chargingstation). The battery 622, in other embodiments, may alternatively plugdirectly into a wall outlet, or the charging station may be wall mountedor plug directly into a wall outlet.

In some embodiments, the energy storage device is or includes a bank ofcapacitors, where the capacitors are configured to charge and releaseelectrical energy in a relatively short (e.g., less than 10 seconds),high-powered output. In some such embodiments, some of the capacitors ofthe bank are coupled with one another in groups (e.g., series orparallel), and the groups are configured to output sequentially in timewith respect to one another. Accordingly, the capacitors arespecifically configured to be able to power the motor to start theengine 610 without much additional energy storage capacity so as to berelatively compact in size and inexpensive. Use of capacitors may alsoallow for faster charging when compared to batteries, such as fastercharging on the charging station 624 (FIG. 7).

In contemplated embodiments, the starter motor is configured to drawpower from the engine 610, such as during periods of lesser loads on theengine. The starter motor is then driven by the engine 610 to provide anelectric output. The electric output may then be routed by the ECU orotherwise to the charge the energy storage device. Such a system may beparticularly useful for an engine driving an alternator of a portablegenerator, where the alternator may temporarily be powered by the energystorage device to start the engine and then, once the engine hasstarted, the alternator may be used to recharge the energy storagedevice.

Referring to FIG. 8, the battery is configured to be inserted (e.g.,dropped, lowered, placed) into a receiving port 626 integrated with theengine. Integrating the receiving port with the engine reduces theassembly burdens for manufacturing outdoor power equipment, as disclosedabove. However in contemplated embodiments, the receiving port may notbe integrated with the engine. For example, FIG. 7 shows a chargingstation 624 or charging port, which may be similar to such a port on adeck of the engine.

In some embodiments, the battery 622 has a cross section forming anisosceles trapezoid, triangle, diamond, or other wedge shape, or shapehaving a narrower lower portion 628 relative to an upper portion 630 incontact with the receiving port 626. The receiving port 626 is contoured(e.g., V-shaped, U-shaped, etc.) to receive the battery 622, which maybe guided into position by interfacing with the contours of thereceiving port 626 and gravity.

In some embodiments, the battery 622 includes slots or grips 632 forlifting and holding the battery 622. A locking mechanism, such as a hookor latch may snap into place when the battery 622 is inserted into thereceiving port 626 and hold the battery 622 in the receiving port 626.Pinching the grips 632 together may release the locking mechanism toallow removal of the battery 622 from the receiving port 626.

According to an exemplary embodiment, the starter system furtherincludes a switch 636 (e.g., toggle, lever, key) that is integrated withthe battery 622, the receiving port 626, or elsewhere on the engine 610.As shown in FIGS. 8-9, the switch 636 may rotate from an off position(FIG. 8), where the battery 622 is not electrically connected tocomponents of the engine 610 (e.g., starter motor, ECU), to an onposition (FIG. 9), where the battery 622 is electrically connected tothe components. In other embodiments, rotation of the switch 636 also oralternatively engages the locking mechanism to hold the battery 622 inthe receiving port 626. In various contemplated embodiments, the switch636 may be configured to interrupt electrical connectivity of thebattery, the control circuit, or both.

According to an exemplary embodiment, the starter system includes aninterface, such as a button 634 on the receiving port 626. The button634 faces outward and is accessible when the battery 622 is seated inthe receiving port 626. In some embodiments, the interface allows theoperator to start the engine via the starter system. In otherembodiments, the interface may be used to initiate charging of thebattery or another function.

According to an exemplary embodiment, the electrical control circuitsshown in FIGS. 10-11 are each configured provide hard-wired logic for astarter system according to the disclosure provided herein. In someembodiments, each circuit contains essentially all analog parts. In someembodiments, each circuit or another such circuit is configured todetect when the bail closes (or opens) a switch (see, e.g., switch 518as shown in FIG. 5). In other embodiments, a circuit is configured tosense when the brake is pulled (see, e.g., brake pad 514 as shown inFIG. 5), and then to enable ignition of the engine. In othercontemplated embodiments, a circuit may be further configured to sensevibration of the engine or Venturi vacuum strength in the carburetor,and cut power to the motor when the associated information indicatesthat the engine is running.

According to an exemplary embodiment, the circuits of FIGS. 10-11 arecontained on circuit boards that are integrated with the engine (see,e.g., controller 132 as shown in FIG. 1), and may be fully powered bythe battery or other on-board source. Accordingly, the circuits mayrequire no electrical interface to components of the lawn mower or otheroutdoor power equipment aside from those carried by or integrated withthe engine. No additional wiring or hook ups are required. Accordingly,the assembly process for the associated outdoor power equipment may beimproved, as discussed above.

Referring now to FIG. 12, a pressure washer system 710 includes theengine 610 of FIG. 6. To start the engine 610, an operator may press thebutton 634 shown in FIGS. 8-9. In some such embodiments, braking of thesystem may occur via an ignition interrupt that prevents sparks fromigniting fuel and air in a combustion chamber of the engine 610.Resistance provided by the water pump of the pressure washer system 710then slows (i.e., brakes) the engine 610. In other contemplatedembodiments, an engine of a portable generator may use a similar startersystem and battery 622, as well as a similar braking system. Powerprovided by the generator may be used to charge the battery 622 of thestarter system.

Referring now to FIG. 13, outdoor power equipment 810 is illustratedschematically. Outdoor power equipment 810 is similar to outdoor powerequipment 410 described above.

Outdoor power equipment 810 includes an engine 812 and an implement 814(e.g., mower blade, pump, auger, tiller, alternator, brush,log-splitter, etc.) driven by the engine 812. In some embodiments, anelectric motor 816 (e.g., a starter motor) is coupled to the engine 812,and the implement 814 is coupled to a power takeoff 818 of the engine812. A speed sensor 820 may be coupled to the engine 812 to detect thespeed of the engine 812. A run sensor 822 is configured to detect whenthe implement 814 is in a ready-to-run condition. Depending on the typeof outdoor power equipment 810, the run sensor 822 can take differentforms. For example, the run sensor 822 may be a switch configured todetect the state (e.g., engaged or disengaged) of a brake or clutch(e.g., for a lawn mower), a switch configured to detect operatorpresence in the operating position (e.g., a seat switch on a tractor ora hand-actuated switch or bail on a handle), an enable fob or keyconfigured to allow the engine 812 to start when actuated or present andprevent the engine 812 from starting when not actuated or present, aswitch configured to sense water or another fluid (e.g., a capacitivewater detection sensor, a pressure sensor, a flow sensor) to ensure thata pump has sufficient fluid to operate safely (e.g., for a pressurewasher or waste pump).

For example, in a lawn mower including a mower blade as the implement814, the run sensor 822 detects when a brake that selectively preventsthe blade from rotating is in a released position so that the blade isallowed to rotate. The mower blade is in the ready-to-run condition whenthe brake is released. In another example, in a pressure washerincluding a fluid pump as the implement 814, the run sensor 822 detectsa threshold fluid flow through the fluid pump to a spray gun. The fluidpump is in the ready-to-run condition when the threshold fluid flow isdetected (e.g., by flow rate, by flow volume, by fluid pressure, etc.)that is indicative of sufficient fluid supplied to the fluid pump toallow for operation of the fluid pump. In another example of a pressurewasher including a fluid pump as the implement 814, the fluid pump is inthe ready-to-run condition when the run sensor 822 detects the presenceor actuation of an enable key or fob. In some embodiments, the outdoorpower equipment 810 includes more than one run sensor 822 and all therun sensors 822 must be satisfied before the implement 814 is consideredto be in the ready-to-run condition.

A release mechanism 826 (e.g., a bail for a lawn mower, a spray guntrigger for a pressure washer, a start button or switch, etc.) ismovable to an engaged position to put the implement 814 in theready-to-run condition. In a lawn mower example, the release mechanism826 can be a bail connected to a handle 824 and the bail is configuredto allow a user to release the brake by moving the bail to the engagedposition. The run sensor 822 detects that the brake is released, therebyputting the mower blade into the ready-to-run condition. If the bail isnot moved to the engaged position (e.g., when the bail is blocked by aninterlock as described above), the brake is not released and the mowerblade will not be put in the ready-to-run condition.

In a pressure washer example, the release mechanism can be the triggerof a spray gun fluidly connected to a fluid pump. The trigger isconfigured to allow fluid to flow through the spray gun when the triggeris moved to the engaged or open position. The trigger in the openposition allows a threshold fluid flow through the fluid pump that isindicative of the fluid pump in the ready-to-run condition. The runsensor 822 detects the threshold fluid flow. If the threshold fluid flowis not established, the fluid pump is not in the ready-to-run conditionand the ready-to-run condition is not detected by the run sensor 822.For example, this may happen if the pressure washer is not connected toa fluid supply (e.g., a water faucet or outlet), or there is a leak orloose connection between the pressure washer and a fluid supply.Alternatively, in some embodiments, the release mechanism 826 can be astart actuator (e.g., a start push-button or key-switch).

Outdoor power equipment 810 also includes a battery 828 for powering themotor 816 and other components of the outdoor power equipment 810 and anelectric start control module 830 for operating the motor 816. Asillustrated in FIG. 13, the control module 830 is spaced apart from(separate from, distinct from) the engine 812. The control module 830 isconfigured to receive inputs associated with the release mechanism 826and the run sensor 822. In some embodiments, when the release mechanism826 is moved to the engaged position, the release mechanism 826 actuatesa switch 832, which provides a signal to the control module 830. Thesignal may be provided via a mechanical linkage, wirelessly, a hardwiredelectrical connection, or otherwise. The control module 830 checks therun sensor 822 to determine if the implement 814 is in the ready-to-runcondition. When both the switch 832 and the run sensor 822 providesignals or inputs indicating the implement 814 is in the ready-to-runcondition, the control module 830 then actuates the motor 816 to startthe engine 812. Additional information or control logic may also beconfigured to start the engine in combination with the status of theswitch 832, the run sensor 822 and/or other factors. Movement of therelease mechanism 826 to the engaged position can simultaneously providea start signal to the control module 830 via the switch 832 as well asput the implement 814 in the ready-to-run condition as detected by therun sensor 822, such that no additional user operations are required tostart the engine 812.

According to an exemplary embodiment, the control module 830 isconfigured to receive additional inputs from the speed sensor 820. Thespeed sensor 820 provides the control module 830 with informationassociated with the speed of the engine 820. In some embodiments, thespeed sensor 820 is configured to detect when the engine 812 is runningat a threshold speed. When the engine 812 is running at the thresholdspeed, the control module 830 then turns off the motor 816 (e.g.,disengages, disconnects, cuts power to, etc.). In some embodiments, thespeed sensor 820 is a component of or otherwise coupled to an ignitioncoil of the engine to detect the engine speed. In other embodiments, thespeed sensor 820 is a component of or otherwise coupled to a governor todetect the engine speed.

In contemplated embodiments, the control module 830 associated with thestart system may receive additional or different inputs used to controlstarting of the engine, such input from a sensor configured to indicatewhether the outdoor power equipment has moved recently. Movement of anaxle or wheels of such outdoor power equipment may trigger a sensor thatprovides a signal to the control module. The signal, in combination withan electric timer providing time-related context for the movement, mayserve as an additional indicator that the operator intends to activatethe engine. In contemplated embodiments, the control module 830 includesa timer and is configured to deactivate the motor if the engine has notstarted within a predetermined amount of time. In some contemplatedembodiments, the control module 830 includes a temperature sensor and isconfigured to prime the engine with an automated primer pump or adjustthe choke or throttle plate if ambient temperature is above or below apredetermined temperature, if a portion of the engine is above or belowa predetermined temperature, or if the difference between ambient andengine temperature is above or below a predetermined value. Incontemplated embodiments, the control module 830 may also provide asignal output to the operator, such as a visible indicator on a displaycoupled to the handle or engine, or an audible alert. In some suchembodiments, the signal output may include as an error message, alow-fuel message, a replace-oil message, or another such message.

Referring now to FIG. 14, the control module 830 is illustratedaccording to an exemplary embodiment. The control module 830 includes ahousing 834, a controller 836 configured to implement control logic foroperation of the outdoor power equipment 810, a connector 838 configuredto be electrically coupled to a release assembly wiring harness 840, anda connector 842 configured to be electrically coupled to the electricmotor 816. The connectors 838 and 842 are located on opposite sides ofthe housing 834 to accommodate connecting the control module 830 inlinewith one or more wiring harnesses. The controller 836 is positionedwithin the housing 834. In some embodiments, the control module 830includes a connector 844 configured to be electrically coupled to thespeed sensor 820. The connector 844 is located on an opposite side ofthe housing 834 from one of the connectors 838 and 842. In someembodiments, the switch 832 is a component of the control module 830 andis positioned within the housing 834.

In some embodiments, the control module 830 also includes one or moreconnectors 846 and 848 configured to be electrically coupled to a runsensor 822 to provide inputs from the run sensor 822 to the controller836. The run sensors 822 are considered to be connected in parallel tothe control module 830. Alternatively, more than one run sensor 822 canbe connected to a single connector 846 so that the controller 836receives a single run sensor input, but only when all of the run sensors822 are satisfied that the implement 814 is in the ready-to-runcondition. In such an embodiment, the run sensors 822 are considered tobe connected in series to the control module 830. In some embodiments,the input from the run sensor is provided via a wiring harness (e.g.,the release assembly wiring harness 840), electrically coupled toconnectors 838 or 842, so no separate connector for a run sensor isrequired to provide a run sensor input to the controller 836. Eachconnector 846 and 848 is located on an opposite side of the housing 834from one of the connectors 838 and 842.

The controller 836 may include components configured to implement hardwired control logic or a processing circuit. The processing circuit caninclude a processor and memory device. The processor can be implementedas a general purpose processor, an application specific integratedcircuit (ASIC), one or more field programmable gate arrays (FPGAs), agroup of processing components, or other suitable electronic processingcomponents. The memory device (e.g., memory, memory unit, storagedevice, etc.) is one or more devices (e.g., RAM, ROM, Flash memory, harddisk storage, etc.) for storing data and/or computer code for completingor facilitating the various processes, layers and modules described inthe present application. The memory device may be or include volatilememory or non-volatile memory. The memory device may include databasecomponents, object code components, script components, or any other typeof information structure for supporting the various activities andinformation structures described in the present application. Accordingto an exemplary embodiment, the memory device is communicably connectedto the processor via the processing circuit and includes computer codefor executing (e.g., by processing circuit and/or processor) one or moreprocesses described herein.

The release assembly wiring harness 840 electrically couples theelectric motor 816, the run sensor 822, and the battery 828 together.For example, in the lawn mower example, the release assembly wiringharness is the bail wiring harness electrically connecting the releaseassembly including the release mechanism or bail 826 to the electricmotor 816 and the motor 816. By connecting the connector 838 to therelease assembly wiring harness 840 (e.g., the bail wiring harness of alawn mower) and connecting the connector 842 to the electric motor 816,the control module 830 is electrically coupled to the release assemblywiring harness 840.

By connecting the control module 830 to exiting wiring, outdoor powerequipment configured to be pull started (e.g., by a recoil starter) isconverted to electric start. The control module 830 is easily connectedinline with existing wiring, thereby eliminating the need for addingadditional wiring or significantly rerouting wiring for an electricstart outdoor power equipment model as compared to a pull start outdoorpower equipment model. The control module 830 is relatively small insize and light weight. This allows the control module 830 to beconnected to existing wiring and not physically mounted to any othercomponent of the outdoor power equipment. That is, once connected to theexisting wiring, the control module 830 is free to remain otherwiseunsupported (e.g. dangle with the existing wiring harnesses) by a mount,bracket, or other physical support structure on the outdoor powerequipment. The control module 830 allows a manufacturer to provide anoutdoor power equipment product available as either a pull start modelor an electric start model while simplifying the manufacturing process.The manufacturing process is simplified because the control module 830that converts the outdoor power equipment to electric start is connectedto existing components (i.e., the release assembly wiring harness 840and the electric motor 816) of the pull start outdoor power equipmentand does not require a separate physical mounting structure.

The construction and arrangements of the starter system for an engine,as shown in the various exemplary embodiments, are illustrative only.Although only a few embodiments have been described in detail in thisdisclosure, many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter described herein. Someelements shown as integrally formed may be constructed of multiple partsor elements, the position of elements may be reversed or otherwisevaried, and the nature or number of discrete elements or positions maybe altered or varied. The order or sequence of any process, logicalalgorithm, or method steps may be varied or re-sequenced according toalternative embodiments. Other substitutions, modifications, changes andomissions may also be made in the design, operating conditions andarrangement of the various exemplary embodiments without departing fromthe scope of the present invention.

What is claimed is:
 1. Outdoor power equipment, comprising: an internalcombustion engine including an engine cover; an electric motorconfigured to start the internal combustion engine; a battery receivingport; a rechargeable battery removably attached to the battery receivingport, wherein the rechargeable battery is configured to power theelectric motor to start the engine; an implement driven by the internalcombustion engine; a release mechanism movable to an engaged position toput the implement in a ready-to-run condition in which the implement isready to be driven by the internal combustion engine; a run sensorconfigured to detect the ready-to-run condition; a switch actuated bythe release mechanism; and a control module coupled to the switch sothat the switch provides a signal to the control module when the releasemechanism is in the engaged position and the control module turns on theelectric motor to start the internal combustion engine in response tothe signal from the switch and the run sensor detecting the ready-to-runcondition.
 2. The outdoor power equipment of claim 1, wherein thecontrol module is spaced apart from the internal combustion engine. 3.The outdoor power equipment of claim 1, wherein the switch is acomponent of the control module.
 4. The outdoor power equipment of claim1, wherein the battery receiving port is integrated with the enginecover.
 5. The outdoor power equipment of claim 4, further comprising: alocking mechanism configured to hold the rechargeable battery in thebattery receiving port.
 6. The outdoor power equipment of claim 5,wherein the locking mechanism is configured to be released by a user toallow removal of the rechargeable battery from the battery receivingport.
 7. The outdoor power equipment of claim 1, wherein the electricstart control module further comprises: a housing, a first connectorconfigured to electrically connect to a release mechanism wiringharness, and a second connector configured to electrically connect tothe starter motor, wherein the first connector and the second connectorare located on opposite sides of the housing.
 8. The outdoor powerequipment of claim 1, further comprising: an engine speed sensor,configured to detect when the internal combustion engine is running at athreshold speed, wherein the engine speed sensor is coupled to thecontrol module, and wherein the control module turns off the electricmotor when the engine speed sensor detects the threshold speed.
 9. Theoutdoor power equipment of claim 8, further comprising: a lockingmechanism configured to hold the rechargeable battery in the batteryreceiving port, wherein the battery receiving port is integrated withthe engine cover, wherein the locking mechanism is configured to bereleased by a user to allow removal of the rechargeable battery from thebattery receiving port.
 10. The outdoor power equipment of claim 8,further comprising: wherein the battery receiving port is integratedwith the engine cover.
 11. The outdoor power equipment of claim 8,wherein the control module further comprises: a housing, a firstconnector configured to electrically connect to a release mechanismwiring harness, and a second connector configured to electricallyconnect to the electric motor, wherein the first connector and thesecond connector are located on opposite sides of the housing.
 12. Theoutdoor power equipment of claim 8, further comprising: a lockingmechanism configured to hold the rechargeable battery in the batteryreceiving port, wherein the battery receiving port is integrated withthe engine cover.
 13. The outdoor power equipment of claim 8, furthercomprising: a locking mechanism configured to hold the rechargeablebattery in the battery receiving port.
 14. The outdoor power equipmentof claim 8, wherein the control module further comprises: a housing, afirst connector configured to electrically connect to a releasemechanism wiring harness, and a second connector configured toelectrically connect to the electric motor, wherein the first connectorand the second connector are located on opposite sides of the housing.15. The outdoor power equipment of claim 1, further comprising: alocking mechanism configured to hold the rechargeable battery in thebattery receiving port.
 16. The outdoor power equipment of claim 15,wherein the control module further comprises: a housing, a firstconnector configured to electrically connect to a release mechanismwiring harness, and a second connector configured to electricallyconnect to the electric motor, wherein the first connector and thesecond connector are located on opposite sides of the housing.
 17. Theoutdoor power equipment of claim 15, wherein the locking mechanism isconfigured to be released by a user to allow removal of the rechargeablebattery from the battery receiving port; and wherein the control modulefurther comprises: a housing, a first connector configured toelectrically connect to a release mechanism wiring harness, and a secondconnector configured to electrically connect to the electric motor,wherein the first connector and the second connector are located onopposite sides of the housing.
 18. The outdoor power equipment of claim15, wherein the battery receiving port is integrated with the enginecover; and wherein the control module further comprises: a housing, afirst connector configured to electrically connect to a releasemechanism wiring harness, and a second connector configured toelectrically connect to the electric motor, wherein the first connectorand the second connector are located on opposite sides of the housing.19. The outdoor power equipment of claim 18, wherein the lockingmechanism is configured to be released by a user to allow removal of therechargeable battery from the battery receiving port.
 20. The outdoorpower equipment of claim 15, wherein the locking mechanism is configuredto be released by a user to allow removal of the rechargeable batteryfrom the battery receiving port.